1968 DATSUN 510 manual transmission

CHAPTER
ONE

GENERAL
INFORMATION

This
manual

provides
maintenance
informa

tIon
on
the
Datsun
510
Series
and
521
Series
of

vehlcles
The
510
Series
includes
the
two
door

sedan
four
door
sedan
and
station

wagon
The

521
Senes
IS
the

pIck

up
truck

Coverage
is
from

1968

through
1972
models

All
models
use
the
L16

engme
a
96
horse

power
four

cylmder
overhead
camshaft

design

The
510
has
a

fully
synchronized
four

speed

manual
or
three

speed
automatic
transmisSIon

The
521
has
a
four

speed
manual
transmission

only
In
1972

horsepower
ratIng
was

lowered

to
92

horsepower
due
to

changes
m
emission

control
device

requirements
Figure
1
is

an
over

all
view
of
the
four
door
sedan

Figure
2
shows

the

station

wagon
and

Figure
3
illustrates
the

pick
up
truck

Over
the

years
the
510
and
521
series
have

remained

essentIally
the
same
with
the

excep

tion
of

changes
to
the

emISsion
control

systems

and
overall

body
stylmg
In
this
manual

every

effort
has
been
made
to

pinpoint
significant
c
if

ferences
between
model

years

The
use
of

SpecIal
tools
and
test

equipment

has
been
avoided
wherever

possible
When

necessary
special
tools
and
test

equipment
are

illustrated
either
in
actual
use
or
alone
A
well

equipped
mecharuc

may
find
he
can

substitute
similar
tools
or
make
his

own
to
fulfill
a
e

Ii

ment

Recommendations
are

occasionally
made
to

refer
servIce
or
mamtenance
to
a
Datsun
dealer

or
a

SpecIaliSt
in
a

specIfied
field
In
these
cases

work
WIll

probably
be
done
more

qUlckly
and

economIcally
than
if
the
mecharuc

performs

them
himself

MODEL
IDENTIFICATION

Body
Number
Plate

The

body
number
IS

stamped
on
the
fire
wall

in
the

engine
compartment
The
numbers

give

the
chasSIS
model
and
serial
number

Model
Identification
Plate

The
model
Identification

plate
Figure
4
is

mounted
WIthin
the

engine

compartment
TIns

plate
gIves
engine
number
and
veh1cle

number

Engine
Identification

The

engine
identrlicatlon

marking
is

stamped

on
the

right
hand
SIde
of
the

cylinder
block

just

below
the
third
and
fourth

sp8l
k

plugs

Model
Identification
Numbel
ll

The

following
numbers
have
been

assigned
to

the
510
and
52
I
Series

vehicles

oj

4

CHAPTER
ONE

chassIs

number
Write
the
numbers
down
and

carry
them
ill

your
wallet

Service
Hints

Throughout
thIs

manual
keep
two
conven

bons

ill
mmd
Front
refers
to
the
front
of
the

vehicle
The
left
and

nght
sides
of
the

ve

hicle
refer
to
a

person
sittIng
ill
the

car

facing

forward
For

example
the

steenng
wheelIS

on

the
left
hand
Side
All
dimensIOns
and

capacities

are
expressed

ill
units
fanuhar

to
a
Umted

States

mechaniC
such
as
illches
and

pounds
Metric

measurements

are
also

given
Metnc

tools
are

reqUITed
to
work

on
the
Datsun
CD

DATSUN

IENGINE
CAPACITY

IMAX
HP
RPM

IWHEELBASE

IENGINE
NUMBER

FAR
NO

NlSSAN

MOTOR

co
LTD

YOKOHAMA
JAPAN
TYPEI
510

1595
cc

961P
6600

rpm

mm

L

1
00988

P61
l
O
1
l
M

Table
1
MAIN
SPECIFICATIONS

AND
DIMENSIONS

r
ITEM
Sedan

Wagon
Plm

up

EnglDe
Type
L16

L16
L16

Valve

Arrangement
Overhead

Cam
Overhead
Cam
Overhead
Cam

Bore
3
26n
ID
83mm

3
2677
ID
83mm
3
2677
ID
83mm

Stroke
2902
ID

73
7mm
2
902
ID

73
7mm
2
902
In

73
7mm

Displacement
97
3
cu
ID

l595cc
97
3
cu
In

l595cc
97
3
cu
ID
1595cc

CompressIOn
Ratio
851

851
851

MaXimum
SAE

Hompower
96

@
5

600

rpm
96

@
5
600

rpm
96

@
5
600

rpm

MaXimum
SAE

Torque
998ft
Ib
138

kg
m
998ft
Ib
138

kg
m

9911
ft
Ib
138

kg
m

Fuel
Octane
85

85
85

Lengtb
1622
ID

4
12Omm
163
2
ID
4
I45mm
168
9
ID
4
290mm

Width

61
4
ID

l
560mm
61
4
ID
1
560mm
62
8
In

Cl
595mm

Height
55
lID
1
400mm
565
ID

Cl
435mm
60
8
ID

Cl
545mm

Wheelbase

95
3
ID

2
42Omm

95
3
ID

2
420mm
99
6
In

2
530mm

Room

Space

Inner

Length
63
3
In
1
61Omm
673
ID

1
710mm
72
8
ID

1
850mm

Inner
Width

499
ID
1
27Omm

507
ID

1
29Omm
563
In

1
430mm

Inner

Height
44
4
In
1
130mm

44
61D
1
135mm
15
7
ID

399mm

Tread

Front

50
4
ID

28Omm
502
In
1
275mm
492
In
1
250mm

Rear
504
In

1
280mm
496
In

Cl
260mm
499
ID
1
267mm

Road

Clearance
741n

l88mm
64
ID
l63mm
787
ID
200mm

Weight

4

Speed
2
0611b
935

kg
2
138
Ib

970

kg
2
127
Ib
965

kg

Automatic

2
114Ib
959

kg
2
182
Ib
990

kg

Minimum

Turning
RadiUS
157ft
48m

157ft
48m
171
ft
52m

Seating

Capaaty
5

5
2

Battery

Volt

12

12
12

Capacity
400rSOAH

400r50AH
40
or
60
AH

Connection

Negative
ground
Negative
ground
Negative
ground

Fuel

Tank

Capaaty
11

9

gal
45
liter
11
9

gal
45
liter
108

gal

41J
r

011

Pan

Capacity
42

qts
40

liter
4
2

qb
40
liter

1
06

gal
40
Iller

011
Filter

Capaaty
74

ql
07
liter
74

ql
0
7
liter
1
48

Pint
0
7
liter

Transmission

Capaaty
1
8

ql
1
7
liter

18

ql
1
7
Iller
2
11

qt
20
Iller

Dlflerenbal

Capaaty
85

ql
80
liter
11

ql
1
0
liter
87

ql
0
83
lIter

Coolant

Capaaty
7
2

ql
6
8
liter
7
2

ql
6
8
lIter
7
2

qt
6
8
Iller

Clutch

Type

Dry
Single
diSC

Dry
slDgle
diSC

Dry
slDgle
diSC

Draphragm
spnng
Diaphragm

spnng
Diaphragm

spnng
l

GENERAL
INFORMATION
5

Table
1
MAIN

SPECIFICATIONS
AND
DIMENSIONS
continued

Suspension
Rear
Sedan
Wagon
Pick

up

Manual
Automatic
Manual
Automatic
Manual

HypoJd
Hypoid
Hypold

ReCIrculating
ball
ReCIrculating
ball
ReCirculating
ball

DIsc
DIsc
Drum

Drum
Drum
Drum

Mechanical
rear
wheels
Mechanical
rear
wheels
Mechanical
rear
wheels

Independent
strut

type
Independent
strut

type
Independent
torsion
bar

with
tension
rods
and
with
tension
rods
and

stabilizer
stabilIZer

Independent
semi

trailing
Semi

elliptiC
leaf

spring
Semi

elliptic
leaf

spnng

arms
wrtII
coli

springs
and

shock
absorbers

5
6O
13
4PR
5
6O
13
4PR
600
14
6PRLT
ITEM

Transmission

Type

Final
Gear

Type

Steering
Gear

Type

Brake

Front

Rear

Parking
Brake

Suspension
Front

Tires

6
2
Q
1
C
S

PA
l
PlLlU

EN
4
1
AJ
E

Dt7
A

1
1
1

2
A
ru
r
f
f
A

I
III

r
c

o
I
pP
D

LA
I
tV
r
IL

c

W

L
L
l
G

ftiv
TJ

dE
IJ
S
prlc
I

u

F
l
e

p
f
vi
Ii

ftl
1
3

l

1t
J
p7
5

PrlV

B4dc
u
11
1

S
t
f
PT

f
L
UJ
ff
zr
F

T
ff

lfo

1oo

4

t

M

0

IY
AJ
to
BTOL

@
OD

2

lP

S

PAtl
pI
c

5
IN
G

ex
Sf

0103
I
D
0
3
O

j

oo

0
0
0
to

l
c

o

0
0

2
JP
t
UE

SEIT
A

C
1

J

12
CHAPTER
THREE

13
IMPROPER
IDLE

MIXTURE

Roats

slowly
between

13
17
14
SMALl
SPARK

GAP
or
DEFECTIVE

POINTS

Slight
float
between

14
16

ignItIOn
switch
If
the
starter
still
fails
to
crank

properly
remove
the
starter
and
test
it

2
Starter
turns
but
does
not

engage
with

engine

This
trouble
is

usually
a
defective

pInion
or
sole

noid

shlfting
fork

It

may
also
be
that
the
teeth

on
the

pInion
flywheel
ring
gear
or
both
are

worn
down
too
far
to

engage

properly

3
Starter

engages
but
will
not

dISengage
when

IgmtlOn
switch
IS
released

TIns
trouble
is

usually
caused

by
a

sticking
sole

nOid
but

occasionally
the

pmlOn
can

jam
on
the

flywheel
With
manual
transmissions
the

pinion

can
be

temporanly
freed

by
rockmg
the
car
in

high

gear
Naturally
this
IS
not

poSSible
in
auto

matics
the
starter
must
be
removed

4
Loud

grinding
noISes
when
starter
runs

TIns

usually
means
the
teeth
on
the

pinion

and
or

flywheel
are
not

meshing
properly
It

may
also
mean
the
over

running
clutch
IS
broken

In
the
first
case
remove
the
starter
and

examine

the

gear
teeth
In
the
latter
remove
the
starter

and

replace
the

pmion
dnve

assembly

CHARGING
SYSTEM

Charging
system
troubles

may
be
in
the
alter

nator

voltage
regulator
or
fan
belt
The
follow

ing
symptoms
are

typical

1
Alternator

warning

lamp
does
not
come
on

when

IgmtlOn
is

turned
on

This

may
indicate
a
defective

ignition
switch

battery
voltage

regulator
or

lamp
Frrst

try
to
15
HEAD
GASKET

LEAK

Roats
between
5
19
16
RESTRICTm

EXHAUST
SYSTEM

Normal
when
first

started

Drops
to
0
as

rpm
Increases

May

eventually
rrse
to

about
16

start
the
car
If
it
doesn
t
start
check

the

igllltlon

sWitch
and

battery

If
the
car
starts
find
the

voltage
regulator
and

disconnect
the
wlute
red
Wire
this
is
the

lamp

wire
Ground
the

wire
If
the

lamp
hghts
the

voltage
regulator
is
defective
not

properly

grounded
try
tightening
the

mounting
screws

or
the
alternator
brushes
are
not

contactmg
the

commutator
If
the

lamp
does
not

light
when
the

wire
IS

grounded
the

lamp
is

probably
burned

out

replace
It

2
Alternator

warning
lamp
comes
on
and

stays
on

This

usually
mdicates
that
no

chargmg
is

takmg

place
Frrst
check
the
fan
belt

tension
and

adlust

if

necessary
Check
the

battery
condition
with

the

hydrometer
and
check
all
electrical
connec

tions
m
the

chargmg
system
Fmally
isolate
the

trouble
to
the
alternator
or

voltage
regulator

3
Alternator

warmng

lamp
flashes
erratically

This

usually
indicates
the

chargmg
system
is

workmg
intermittently
Check
the
fan
belt
ten

sion
and
all
electncal
connections
m
the

charg

ing
system
Check
alternator
brushes
and
cODlh

tlon
of
the
commutator

4

Baltery
reqUires
frequent
additiOns

of
water

or

lamps
require
frequent

replacement

The
alternator
IS

probably
overchargmg
the
bat

tery
The

voltage
regulator
is

probably
faulty

check
it

using
the

procedures
given
in

Chaper

Nme

5
ExceSSive

noISe

from
he
alternator

Check
for
loose
alternator

mountmg
The

ENGINE

37

CD

4

11lL

8

311
@
2S

10

32
@
@
24

33
Q
23

1
21

rl
qp

12
26

27

19
34

30

31
1
25

@
24

W
32
@

30

33
0

21

28
tJ

2S
ctJ5J

27

20

II

27

Inner
valve
seat

spnng

1
Camshaft

10
Camshaft
cham
19
Intake
valve

28
Valve
011
seal

2
Camshaft
dowel

11
Chain
tensloner
20
Exhaut
valve

29
Valve
rocker

4
Cam

locating
plate
12
Hex
bolt
21
Valve

spnng
30
Valve
rocker
WIth

pad

5

Spnng
washer

13

Spnng
washer
22
Valve

spnng
31
Valve
rocker

Pivot

6
Hex
bolt

14
Chain
tension
Side

gUide
23
Valve

retamer
32
Pivot
ICICk

nul

7
Cam
sprocket
15
Chain
tension
slack

gUide
24
Valve
collet

33
Rocker

retainer

8
Cam

gear
bolt
16

Spnng
washer
25
Rocker

valve
guide
34
Rocker

valve

spnng

9
Fuel

pump
earn

assembly
17
Hex
bolt
26

Valve
seat
35

Rocker

bushing

vious

chapter
for

specmcaoons
and
mamten

ance
CARBURETOR

The
carburetor

IS
a

smgle
two
barrel
down

draft

type
From
1968

through
1971
the
car

buretor

on
manual
transmissIOn
models

has
a

hand
choke

control
1972
models
are

eqUIpped

With
an
automatic
choke
much
the

same
as
has

been

used
on
all

automaoc
transmISSion
models
FUEL
PUMP

The
fuel

pump
IS
on
the
front

right
hand
Side

of
the

engme
Just
below
the
rocker
arm
cover

It

IS
a

diaphragm
type
dnven

by
the
camshaft

FUEL
SYSTEM
69

CARBURETOR

The
carburetor
IS
an
Hltach1

Type
DAF328

Several
varIations
are
used

dependmg
on
the

model

year

type
of
transmissIOn
and
the
emIS

SIon
control

system
The
dIfferent
models
are

the
same
as
far
as
basiC

operation
IS
concerned

Therefore
the

followmg
dISCUSSIon
covers
a

typIcal
carburetor
The

automatIc
choke
IS
used

on
automatIc
transmISSIon
and
1972
models

only
All
other
chokes
are
manual

Refer
to

Figure
8
The
carburetor
conSIsts
of

a

pnmary
system
used
m
normal

runnmg
and
a

secondary
system
used
for

hIgh
speed
or

heavy

load

operatIons

CARBURETOR
ADJUSTMENT

Idling
Adjustment

Idle

adjustment
IS
made

by
the
throttle

adjust

and
Idle

adjust
screws
both
of
wh1ch
are
located

at
the
bottom
of
the
carburetor

1

Screw
the
Idle

adjust
screw
all
the

way
in

to

the

fully
closed

pOSItIon
Do
not
over

tIghten

CD

6
2
Unscrew
the
Idle

adjust
screw

approXImately

three

cor
nplete
turns

3
Screw
m
the
throttle

adjust
screw
two
or
three

turns
and
start
the

engui
e

4
Screw
out
the
throttle

adjust
screw

slowly

until
the
onset

roughness
followmg
a

gradu81

speed
drops

5
Screw
m

the
Idle

aOJust
screw
untIl
the

engme

runs

smoothly
at
the

hIghest

speed

6

Readjust
the
throttle
screw
to

drop
the

engme

speed
Repeat
these

adjustments
untIl
a
smooth

engme
speed
at
the

proper
Idle

rpm
IS
ach1eved

Refer
to
the
tune

up
chapter
for

proper
rpm

Fuel
Level

Adjustment

Constant
fuel
level
IS
mamtamed

by
the
float

and
the
needle
valve

Figure
9
sb
ws
the
fuel

level

system
wlthm
the
carburetor
If
the
level
IS

at
the
lIne
on
the

f
lel
reservOir
level
is

properly

set
If
not

adjust
It

by
bendmg
the
float
seat

Adjust
the

gap
between
the
valve
stem
and
the

float
seat
to
00591
m

1
5mm
with
the
float

fully
luted

up
by
bendmg
the
float

stopper

1213141516

20

I

h

r

1
Secondary
main

nozzle

2
Secondary
small
venturi
10

Secondary
bypass
hole
18

Primary
slow
air
bleed

3

Secondary
main
air
bleed
11

Secondary
throttle
valve
19
Air
vent

4

Secondary
slow

Jet
12
Choke
valve
20
Level

gauge

5

Secondary
slow
air
bleed
13

Primary
main
air
bleed
21

Primary
main

Jet

6
Needle
valve
14

Primary
main
nozzle
22
Idle
limit
screw

7
Float
15
Economizer
bleed
23
Idle
hole

8

Secondary
emulSion
tube
16

Primary
slow

let
24

Bypass
hole

9

Secondary
main

Jet
17

Primary
economizer
25

Primary
throttle
valve

134

CHAPTER

ELEVEN

CLUTCH
SERVICE
DATA

AND

SPECIF1CATIONS

Table
1

proVIdes
serVIce
data

and

specifica

tIons
for
the
clutch

system

TRANSMISSION

Description

Datsuns
are

eqUIpped
with
either

an
auto

matic
or
manual
transrmSSIOn

Due
to
the
com

pleXity
of
the
unIt
and

the
need
for

special
tools

and

knowledge
overhaul

of
the
automatic
trans

mISSIon
is
not

covered
In
thIS
manual
Auto

matIc
transmISSIOn

checks
and

adjustments
are

given
later
m
thIS

chapter
Reparr
and
mainte

nance

should
be
referred
to

a
Datsun
dealer

or

qualIfied
mechamc

The
manual
transmission
is

a
four
forward

Table
1
speed
unlt
controlled
With
a
floor

mounted
lever

It
consIsts
of
transrmSSIOn

case
rear
extensIOn

housing
and

gear
assembly
The
clutch

housmg

and
transmissIOn

case
are
a

sIngle
unIt
The

rear

extension

housmg
is

detachable

Figure
12
shows

the
4
forward

speed
transmission

Transmission

Removal

Removal
of
the

transmIssion
from
dIfferent

models

Varles

accordmg
to
the

dIfferent
struc

ture
Involved
The

following
procedures

gen

erally

apply
to
all

types

Important
dIfferences

are
noted

1
Prom

InsIde
the
vehicle

remove
the
floor

covenng
around
the

gear
shift

so
that
the
shIft

lever
can
be
removed

2
Jack

up
the
vehIcle
and

support
it
with
four

CLUTCH
SERVICE
DATA
AND
SPECIFICATIONS

Pressure

Spring

Free

length

Fitted

length
and
load

Out
of

rlght

angle

MInimum

sprmg
force

Clutch
Release
Lever

Release

bearlng
to

dlaphragm
clearance

Diaphragm
sprlng
to

flywheel
height

Release

lever
to

flywheel
height

Clutch
DISC

FaCing
size

Outer

dIameter
x
inSide
diameter

x
thlckness

Thickness

Free

Compressed

Number
of

tOrslO
1
springs

Minimum

depth
of
rivet
head

from

faCing
surface

Allowable

facmg
runout

Allowable

spline
free

play

Pressure

Plate

Allowable

refacmg
limit

Clutch
Pedal

Height
when
not

depressed

Free
stroke
of

pedal
head

Pressmg
strength
at
full

stroke

Clutch
Master

Cylinder

Diameter

MaXimum

clearance
between

cylinder
and

pIston

Tightening

Torque

Clutch

assembly

securing
bolt
2
059
In
52
3mm

1
149
In
197
4
4
Ib
29
2mm
44
2

kg

o
1968

per
3
937
In
5

per
100mm

15

00472
to
0
0551
In

1
2
to
1
4mm

1732
0
0394
m

44
O
1

Omm

1
988

0
0197
In

505
0
05mm

787
X

5
120
x
0
0140
In
200
x
130
x
3
5mm

o
3386
to
0
3543
m
8
6
to
9
Omm

03012
to
0
3130
m
765

to
7
95mm

6

00118
In
03mm

o
097
In
0
5mm

00157
m
04mm

o
0394

In
1
Omm

8
150
m
207mm

o
984
m
25mm

33
Ib
15

kg

0625
m

15
87mm

00051
m
0
13mm
J

i

r

174
to
188ft
Ib
24

to
2

6

kg
m

148

CHAPTER

ELEVEN

1

Insert

key
in

IgnItion
switch
and
turn
to
first

posltlon

2

Depress
accelerator

pedal
fully
LISten
for

the
solenOId

to
click
If

a
clIck
is
heard
the

solenoid
is

operating
correctly

3

Replace
solenoid
if
click

IS
not
heard
Before

replacing
solenoid
dram

apprOlumately
2

pInts
of
transmission
011
from
tranSmISsion
Re

fill
when
solenoid

replacement
is

complete

4
If
solenoId
IS

operatlng
correctly
but
trouble

persISts
check
WIres
for

continuity
With
electri

cal
tester

Linkage
Inspection
and

Adjustment

To

inspect
and

adjust
the

linkage
on
the

transmission

proceed
as
follows

Figure
4
j

shows
the

linkage
for
column
shift
models
and

Figure
47
shows
the

lInkage
for
floor
shift

models

1
Move
selector
from
P
to
1
and
back

again

several

tImes
If
the

lInkage
is

correct
a

slight

click
sh
uld
be
felt

and
heard
when

the
selector

is

set
at
each

position

2
If
the
lever

position
is

mcorrect
adjust
the

lin

age
in

t
ie
ngin
C
Q1I1

lT
me
t

s9

mat

f46

OSIoI0mm

00197
to

mJ

r2
oN

k
@
FRONT

tion
D
of
the
detent
manual
valve

alignS
with

posItion
D
of
the

pOSItIon
plate
as
shown
in

the
illustrations

Inhibitor
Switc
h

Checks

and

Adjustment

The
inhibItor

SWitch

lights
the
reverse

lamp

and

enables
the
starter
motor
to

operate
in
the

neutral
and

park
positIons
Figure
48
shows
the

construction
and

mountlng
of
the
InhibItor

SWitch
To
check
the
mhIbltor
switch

proceed

as
follows

r

I
5

1
InhIbitor
switch

2
Menual
shalt

3
Washer

4
Nut
5
Manual

plate

6
Washer

7
Nut

8
Inhibitor

switch

9

Range
select
Iner

1
Move
selector
lever
to
reverse

position
and

clieck
that
reverse

lamp
bun

lignts
If

not
in

spect
bulb
and

replace
1f
defectlve
If
bulb
is
all

right
replace
mhibItor
switch

2
Check
for

proper
operation
of
starter
motor

in

neutral
and

park
positions
If
abnormal
check

to

see
that

lInkage
IS
correct
If

linkage
IS
cor

rect
replace
Inhibitor
SWitch